design recommendations

design recommendations
Body Builders Layout Book
1
DESIGN
DESIGN RECOMMENDATIONS
DESIGN RECOMMENDATIONS
INDEX
Page
Fuel System
2-4
Electrical System
4
Cooling System / Climate Control System
5-6
Exhaust System / Ford Body Components
7
Wheels & Tires / Brake Components / TPMS
8
Suspension & Steering / Engine
9
Driveline / Transmission / Frame / Jack
10
Ambulance Builders Guidelines
11
New Vehicle Storage Guidelines
12
www.fleet.ford.com/truckbbas
2016
MODEL YEAR
Body Builders Layout Book
2
DESIGN
FUEL SYSTEM
WARNING:
Before opening the fuel system, relieve fuel pressure
by following the instructions in the Ford Truck Shop
Manual for the appropriate model and model year. The
evaporative emission system contains fuel vapor and
condensed fuel vapor. Although not present in large
quantities, it still presents the danger of explosion or
fire. When welding near fuel system components, all
metallic components should be adequately shielded
and protected from heat or weld splatter. All nonmetallic components should be removed. Removal or
re-installation of any Ford fuel system component
should be performed to the specifications and
instructions found in the Ford Truck Shop Manual for
the appropriate model and model year.
INFORMATION
The following recommendations are intended to assist
in the design and completion of the fuel system
capable of meeting the requirements of F/CMVSS
301. These recommendations are based on testing
and analysis performed by Ford Motor Company.
Since completed vehicles may take many forms, this
list of recommendations cannot cover all possibilities.
Strict adherence to these suggestions will not ensure
that the completed vehicle will comply with F/CMVSS
301. The responsibility for determining compliance to
F/CMVSS 301 regulations is that of the final stage
manufacturer. Accordingly, Ford Motor Company
makes no representations as to the appropriateness
of any particular recommendation in its specific
application to a particular design or act of intermediate
or final stage manufacture.
To verify compliance with F/CMVSS 301, testing of
representative vehicles to applicable F/CMVSS 301
procedures may be necessary. Questions regarding
compliance with F/CMVSS regulations should be
directed to your legal counsel, the National Highway
Traffic Safety Administration, or Transport Canada.
Any alteration or modification of a vehicle’s fuel or
evaporative system may affect the vehicle’s
compliance with applicable federal and state emission
laws, including on-board diagnostics (OBDII) and
evaporative emissions requirements, and may also
effect vehicle performance (driveability, idle quality,
etc.). Vehicle modifiers are responsible for ensuring
that a vehicle, as modified, complies with all
applicable emissions regulations and for obtaining any
necessary federal or state approval or certification
relating to vehicle modification or sale of add-on or
auxiliary parts.
2016
DESIGN RECOMMENDATIONS
FUEL SYSTEM
A. NEW FUEL TANKS
1. The fuel tank should be designed with as few
openings and connections as possible. Openings
and connections generally should be located on the
upper surface of the fuel tank.
2. Fuel tanks should be fitted with an evaporation
control valve having the means to close if the
vehicle is rotated about a longitudinal axis pursuant
to F/CMVSS 301.
3. The tank should be of simple configuration
minimizing sharp surface transitions and protrusions
which may be required for attachment or function.
4. The tank should be strong enough to with stand
instantaneous internal pressure imposed in the
event of crash situations.
5. Hoses connected to the tank should be sufficiently
flexible to permit small movements of the tank
relative to fixed mounting surfaces, without rupture
or disconnection of such hoses in the event of crash
situations.
6. Emission regulations may require an OBDII fuel
tank pressure sensor for the evaporative system.
Any new fuel tank must be tested and comply with
all emission regulations, including evaporative
emissions.
7. Package new tank away from heat sources such as
exhaust.
B. NEW FUEL TANK RETENTION SYSTEMS
1. The retention system should attach the fuel tank to
the frame, between the frame rails, and below the
body of the vehicle with sufficient clearance for
normal body to frame movement under loaded
conditions.
2. A retention system should restrict fuel tank
movement in all possible directions to prevent
contact or rupture with rigid or sharp objects, and
the disconnection of fuel system tubes and hoses
under crash conditions. Retention straps should
avoid sharp edges and tank supports should be
designed with fuel tank compatible surfaces and
edges to the fuel tank.
3. System fasteners and attachments should be
designed to retain the tank during deflections
incurred in crash situations.
C. FUEL FILL SYSTEM
1. Fill system should be sufficiently flexible to prevent
possible rupture or disconnection resulting from
movement of the fuel tank relative to frame during
crash situations. Use the original pickup truck filler if
the fill location is similar to the original pickup truck
location.
2. Any appliance or hardware attachments to the body
in the area of a fuel system component should be
designed, positioned, and secured so as not to
impact any fuel system component during crash
situations.
3. The fuel filler opening area of the body should
provide adequate sealing from the vehicle interior
because holes or cracks in this area may allow fuel
vapors to enter the vehicle interior. Openings should
be sealed with a product which is fuel resistant. See
Figure A on this page.
4. The metal outer end of the fuel fill neck tube
provided by Ford must be properly grounded to the
chassis to dissipate any electrostatic charge that
may be produced and so reduce the possibility of a
spark during fueling. A fill neck support made of
metal would provide a ground path if directly
mounted on the chassis. If the filler neck support is
made of plastic or other non-metallic material, a
ground strap or wire must connect the metal end of
the fuel filler neck and a metal chassis component.
5. Fill openings should be recessed, and caps, when
installed, should be inside the normal body plane.
6. Whenever possible, the fill system should pass
under the body rather than through it. Where
passing through floors and sides, the fill system
should be shielded and have adequate clearance to
surrounding structure. Fuel Filler and Vent Hoses
should maintain a minimum of one inch clearance to
body and surrounding chassis components, except
where the hoses and protective sleeve material
pass through the designed frame opening.
7. Be sure that the fuel tank filler cap is the correct
Ford designated part. Provide adequate hand
clearance for cap installation and correct sealing of
the cap to filler pipe.
8. The recommended horizontal and vertical locations
for the fuel tank filler pipe are shown in the E-Series
and Super Duty F-Series sections of this book.
MODEL YEAR
ISOLATORFILL NECK
ISOLATORFILL NECK
LINOLEUM/CARPET
FLOORING
BODY
SIDE
PANEL
FUEL
FILLER
FRAME
FIGURE A – BODY MOUNTED FUEL FILLER OPENINGS
VEHICLE
ENGINE
FUEL TANK
FUEL FILL KIT P/N
F-Super Duty
Diesel
Chassis Cab
Gas
Wide Frame
Pickup
Diesel
Gas
E-Series Cutaway
FFV
E350/450/
School Bus
Gas
Midship
Aft of axle
Midship
Aft of axle
Box delete
Box removed
Box delete (slow fill fix)
Box removed
8C3Z-9B149-AF
8C3Z-9B149-CF
8C3Z-9B149-BD
8C3Z-9B149-DD
8C3Z-9B149-EF
9C3Z-9B149-B
8C3Z-9B149-L
8C3Z-9B149-J
Aft of axle
9C2Z-9B149-A
9C2Z-9B149-C
Other parts that can be ordered/purchased separately:
PART DESCRIPTION
SERVICE P/N
Support (unskirted body)
E0TZ-9040-A
Label – Unleaded Fuel
D702-9A095-A
Label – Diesel Fuel
E432-9A095-A
(Cont'd next page)
www.fleet.ford.com/truckbbas
Body Builders Layout Book
3
C. FUEL FILL SYSTEM (CONT’D)
9. When installing accessories or equipment, avoid
exposure of fuel and vapor hoses to surfaces with
sharp edges (see Figure B on this page) or high
temperature surfaces (near hot exhaust or coolant).
Also avoid installations which result in the exposure
of these lines to road debris or undercoating.
10. Install or route fuel tank filler hoses and filler vent
hoses as follows:
a) Avoid sags below the horizontal which allow fuel
puddling (i.e., avoid sink traps). See Sink Traps
in Figure B. Fuel trapped in low spots can be
expelled when the cap is removed, even if the
tank is nearly empty.
b) Avoid pinches or kinks, as they restrict fuel filling
or venting. Hose length may require adjusting
depending on second unit body width. See
Kinked Fuel Fill System, Figure B
c) Do not place adjacent hardware such that it may
cut or otherwise damage the filler neck and vent
hoses and cause fuel or vapor leakage (i.e.,
avoid unfriendly surfaces) see Hostile Surfaces,
Figure B.
d) Keep the flow of fuel continuously downward
from the inlet of the fuel filler pipe all the way to
the tank.
e) The filler hose and vent hose must be clear of
moving suspension components so as to
prevent abrasion which can result in fuel
leakage. They should maintain a minimum of 1
inch clearance to body and surrounding chassis
components, except where the hoses and
protective sleeve material pass through the
designed frame opening.
f) Be certain that all clamps are secure and
properly located.
g) The fuel filler and filler vent hoses should not
contain fittings or connections other than those
incorporated in the original design, nor should
they be interconnected with each other in
anyway.
h) Ford released parts should be used.
2016
DESIGN RECOMMENDATIONS
FUEL SYSTEM (Cont'd)
DESIGN
AVOID “SINK TRAPS”
IN THE FUEL FILLER HOSE
PROTECT FROM
SHARP EDGE
TRAPPED
FUEL
SINK TRAPS
AVOID FUEL FILLER
KINKED DUE TO
IMPROPER ROUTING
AVOID FILLER VENT
KINKED DUE TO
IMPROPER ROUTING
FRAME
KINKED FUEL FILL SYSTEM
AVOID JAGGED
EDGE OPENING
FRAME
SPACER
FUEL FILLER
FILLER VENT
HOSTILE SURFACES
FRAME
FIGURE B – FUEL FILL SYSTEM INSTALLATION
CONDITIONS TO BE AVOIDED
D. FUEL TUBES, HOSES AND PUMPS
1. Do not reroute or change the attachment of fuel
lines or fuel vapor hoses. Doing so may alter the
vehicle’s ability to comply with F/CMVSS 301, Fuel
System Integrity, and may adversely affect vehicle
performance by increasing the amount of heat
absorbed by the fuel system or by restricting its
venting.
2. Tubes and hoses should be routed away from and
not attached to members that will move or deform
during crash situations.
3. Tubes and hoses must be sufficiently flexible to
avoid rupture or disconnection resulting from
movement of the engine relative to the frame during
crash situations.
4. Tubes and hoses should be routed away from hot
regions and sharp objects and should be retained
adequately to prevent movement into such regions
or against such objects.
5. Do not add fuel or vapor line flow restrictors as they
can cause engine fuel starvation or abnormally high
fuel tank pressures.
6. Do not install auxiliary fuel pumps. This could cause
the engine to run rich, producing additional exhaust
heat.
7. The special removal tool shown in Figure D on the
next page must be used to open push connectors
installed on flexible fuel lines if the lines need to be
disconnected. The appropriate tool is available from
Ford Customer Service Division.
8. The push connectors on flexible fuel lines, if
disconnected, must be reconnected by snapping
them back into position and installing the
appropriate retainer as shown in Figure D on the
next page.
MODEL YEAR
9. Avoid pinching or kinking of any fuel vapor hose.
(See Figure C below).
BODY SILL
PINCHED FUEL HOSE
TOP OF
FUEL TANK
FIGURE C - PINCHED FUEL VAPOR LINES
10. Each of the fuel lines and fuel vapor hose retention
clips provided by Ford must be used in original
factory locations to prevent misplacement or
movement of the lines.
11. Be certain that the vent valves on top of the fuel
tanks are seated and secure; do not dislodge or
damage them when mounting the second unit body.
If they are unseated, fuel leakage may occur. If
damaged, the vapor vent system may not function,
resulting in increased fuel tank pressure.
12. If a fuel sender is removed for any reason, use a
new gasket when it is reinstalled so as to prevent
fuel leaks. Be certain the fuel sender is seated and
secure on the top of each fuel tank. Do not step
upon or place weight upon the sender during
vehicle manufacture.
13. Fuel filters installed in the fuel supply line must be
of sufficient size to be nonrestrictive to fuel flow and
placed so as to be protected from exposure to
exhaust heat and physical damage. Ford
replacement fuel filters are recommended. Filters
are not to be installed in the fuel return line.
14. Temporary shipping fuel lines are not to be reused.
They should be disposed of in an appropriate
manner.
15. Fuel system components which are disconnected
during manufacturing should be capped or plugged
promptly to prevent possible contamination.
16. When welding near fuel system components, all
metallic components must be adequately shielded
and protected from heat or weld splatter. All
nonmetallic components must be removed.
(Cont'd next page)
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Body Builders Layout Book
4
DESIGN
E. FUEL SYSTEM ACCESS FOR AUXILIARY FUEL
POWERED EQUIPMENT
Precautions similar to those described in this Fuel
System section should be taken in the design and
positioning of a fuel system for auxiliary fuel-powered
equipment. The auxiliary fuel-powered equipment
should be securely mounted so as to withstand forces
during crash situations.
E-Series Super Duty Cutaway, E-Series Super Duty
Stripped Chassis and Super Duty F-Series, aft-of-axle
fuel tanks are equipped with an auxiliary fuel port in the
fuel sender unit. The purpose is to provide a fuel supply
for fuel powered accessories such as generator sets.
Transit vehicles have an auxiliary fuel port located on
the midship fuel tank sender unit.
Final stage manufacturers that utilize the auxiliary fuel
port must install a check valve because of Onboard
Fuel System Diagnostics (OBDII). The system may
affect the vehicle’s compliance with applicable
Federal/State emissions laws. Additional information is
available in Quality Bulletin Q-42, “Auxiliary Fuel Port
Requires Electric Solenoid”; to obtain a copy, log on to
www.fleet.ford.com/truckbbas and select from the list
under the “Bulletins” tab.
All auxiliary fuel ports have a safety cap which must
remain in place until a fuel consuming accessory is
installed.
An E-Series push connector fuel tank kit 9C24-9B210AA, included in dunnage or available from your local
Ford dealer, will attach to the auxiliary fuel port and
accept a 1/4” hose. The kit includes a 90 degree
connector and a screw clamp.
Transit auxiliary fuel port information is available in the
Ford Transit Body and Equipment Mounting Manual
(BEMM), Chapter 3.6 Fuel System, available online at
www.fleet.ford.com/truckbbas under the “Publications”
tab. Additional information is available in Quality
Bulletin Q-42, “Transit Aux Fuel Port Kits”, available
online at www.fleet.ford.com/truckbbas under the
“Bulletins” tab.
Transit vehicles with a gasoline engine have a capped
auxiliary fuel tank port; a 90 degree connector can be
ordered as a service item, part number CK41-9B210A*. The auxiliary fuel line is not offered as a service
item.
Transit vehicles with a diesel engine have a capped
auxiliary fuel tank port; a 90 degree connector can be
ordered as a service item, part number CK41-9B210C*. The auxiliary fuel line is not offered as a service
item.
www.fleet.ford.com/truckbbas
DESIGN RECOMMENDATIONS
FUEL SYSTEM (Cont'd) / ELECTRICAL SYSTEM
REMOVAL TOOL
RETAINER – FUEL TUBE
PUSH CONNECTOR
REMOVAL TOOL
WARNING:
Before opening the fuel system on vehicles with EFI engines,
relieve fuel pressure by following the instructions in the Ford Truck
Shop Manual for the appropriate model and model year.
FIGURE D – FLEXIBLE FUEL LINE PUSH-CONNECT
Remaining Fuel Volume (Gallons) at Auxiliary Tube Shut-off Level
Fuel Tank Capacity
Model
25 Gal
40 Gal
55 Gal
80 Gal
E-Series (Gasoline)
-8.7
12.1
-E-Series (Diesel)
-13
18
-SD F-Series (Gasoline)
-5.2
--SD F-Series (Diesel)
-4.6
--F-53
---11.7
F-59
-5.2
---Transit (Gasoline)
5
-Transit (Diesel)
7.5
2016
MODEL YEAR
ELECTRICAL SYSTEM
Refer to Bulletin Q-130, “General Electrical Practices”,
available at www.fleet.ford.com/truckbbas under the
“Bulletins” tab.
Body Builders Layout Book
5
2016
DESIGN RECOMMENDATIONS
COOLING SYSTEM / CLIMATE CONTROL SYSTEM
DESIGN
COOLING SYSTEM
1. Equipment such as flashing lights and sirens, spare
tires or any other accessories should not be
installed in the grille area forward of the radiator or
air cleaner air inlet. Doing so restricts proper airflow
through the radiator and engine compartments. ESeries and Super Duty F-Series are illustrated in the
figure below.
2. For proper engine cooling, do not alter, change the
locations of, or remove the original equipment fan,
fan clutch, or shroud.
3. Maintain a 50/50 mixture of ethylene glycol-based
antifreeze-to-water ratio when adding or modifying
the heater system or auxiliary heater system. A
60/40 antifreeze-to-water ratio may be necessary
during winter months in very cold climates. For the
remainder of the year, however, a 50/50 ratio should
be maintained.
4. Upper radiator hoses and heater hoses, which are
added or replaces, should be EPDM-Kevlar
composition. Lower radiator hoses should be
EPDM-Rayon composition.
5. The radiator and fan shroud should not be used as
structural members and additional components
should not be attached.
6. Revisions to the Front End Accessory Drive System
may affect the cooling system/component
performance and are not recommended.
7. Do not alter or modify the automatic transmission
cooling system.
8. The minimum radiator grille opening (excluding all
grille parts) for the E-Series Stripped Chassis, to
provide optimum cooling for the engine, is 300 sq.in.
9. Equipment, hazardous materials markers, or
placards must not obstruct the airflow to the radiator
or the air cleaner inlet on the E-Series Super Duty
Stripped Chassis.
10. The E-Series Super Duty Stripped Chassis engine
compartment must be designed to eliminate any air
circulation restriction that would affect the air
induction or cooling systems. An engine
compartment must provide adequate flow-through
ventilation to prevent local air temperature from
exceeding recommended maximums.
ACCESSORIES SHOULD
NOT BLOCK AIRFLOW
IN SHADED AREAS
CLIMATE CONTROL SYSTEM
1. An Auxiliary Heater A/C Connector Prep Package
can be either standard or optional on E-Series
vehicles for connecting auxiliary climate control
systems to the Ford system. The following items are
important for the maximum efficiency of the
combined systems:
● The connector tubes are under the floor directly
below the driver’s seat.
● The heater supply tube is identified with a white
paint dot and should be connected to the lowest
connection port on the auxiliary heater core.
● The A/C connector tubes have a 20 x 1.5-6g
metric thread for high pressure and 24 x 2.0-6g
metric thread for low pressure.
● If the vehicle is equipped with the auxiliary heaterair conditioner, do not operate the front A/C
system prior to the addition of an auxiliary system.
The system oil could settle in the connector tubes
and not provide lubrication to the compressor.
See Bulletin Q-47, “A/C-Heater Prep Package
(57L) or A/C Prep Package with Rear A/C
Controls
(57X)”,
available
online
at
www.fleet.ford.com/truckbbas
under
the
“Bulletins” tab.
● The
Ford auxiliary blower switch requires an
electric relay for high-speed blower operation; a
relay is included in Ford factory-installed rear
climate control systems.
2. R134-a charge A/C systems must use PAG-type
lubricating oil Motorcraft part number YN-12-D, Ford
part number F2AZ-19577-AD and must meet Ford
specification WSH-M1C231-B. Always use the
same refrigerant and lubricating oil as originally
equipped by Ford.
3. Maintain a 4% suspended oil ratio in the A/C system
for proper compressor lubrication.
4. E-Series A/C and refrigerant oil system are built
from the factory in the following configurations:
GASOLINE
VEHICLE CONFIGURATION
KEEP THIS
AREA CLEAR
R-134a (oz)
R-134a (lb)
PAG Oil (oz)
Front Only
30
1.875
8
Front w/ Optional Prep
Packages
30
1.875
16
5. The 2016 F53/F59 basic stripped chassis vehicles
incorporate a new design A/C suction line GU9Z19E636-A* that must be ordered from Ford
Component Sales in order to properly complete the
A/C system. Ordering information is provided in
SVE Bulletin Q-233, “2016 F53/F59 A/C Line
Change”,
available
online
at
www.fleet.ford.com/truckbbas under the “Bulletins”
tab.
A label stating the total refrigerant charge, type of
refrigerant (R-134a) and type of compressor
lubricant oil (PAG) used must be affixed in a
conspicuous place in the engine compartment.
ENGINE COOLING RADIATOR
AIR CONDITIONER CONDENSER
E-SERIES
SUPER DUTY
MODEL YEAR
F-SERIES
SUPER DUTY
(Cont'd next page)
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Body Builders Layout Book
6
DESIGN
CLIMATE CONTROL SYSTEM (Cont’d)
6. The A/C compressor will cycle during the defrost
mode. A refrigerant shut-off valve for the auxiliary
system may impair compressor lubrication.
7. R-134A charged A/C systems should use barrier
type A/C hose. Barbed fittings and external
clamping may not be compatible with this type of
hose. Swaged, permanent fittings on this type of
hose are recommended.
8. NEVER ATTACH ANY COMPONENT TO THE
TRANSMISSION FILLER AND DIPSTICK TUBE.
9. Auxiliary heater and air conditioning systems hose
routings must consider the following:
● Dynamic engine roll or any system component
which has an operating zone. Make sure there is
adequate clearance (e.g., transmission downshift
linkage, steering column shift linkage).
● Do not route heater or A/C hoses directly over or
near the exhaust system.
● Do not route hoses by attaching to the engine.
● Use only metallic “Y” and “T” type fittings or OEM
approved materials.
● Do not route hose in wheelhouse area.
● Do
not route by sharp edges or moving
component parts. There must be shield protection
from any potential abrasive source.
● When routing in stone kickup area, lines should
be protected by shields. Minimize use of
concentric protective heater hose shields. Limit
length of concentric hose shields to 305 mm
[12in] maximum.
● Where possible, encase added suction lines in
insulating foam from connector location
underbody to the secondary evaporator.
10. For additional information, refer to SVE Bulletin Q148, “Air Conditioning and Front End Accessory
Drive (FEAD) Design Best Practices - E-Series and
F-Series”,
available
online
at
www.fleet.ford.com/truckbbas under the “Bulletins”
tab.
www.fleet.ford.com/truckbbas
DESIGN RECOMMENDATIONS
COOLING SYSTEM / CLIMATE CONTROL SYSTEM (Cont'd)
11. Front End Air Flow:
● There should be nothing mounted in front of or
behind the front end grille opening which could
reduce the effective air flow to the cooling
module.
● Under
no circumstances should there by any
modifications to the fan shroud or stator.
● Do not modify or remove any seals which are part
of the cooling module (i.e., body seals, condenser
seal, radiator seals, snow shield). These shields
are intended to prevent engine heat recirculation
back through the A/C condenser.
12. E-Series Cutaway vehicles ordered with the optional
AUX A/C packages:
● When attaching an aftermarket AUX A/C unit to
an existing OEM front A/C system, the AUX A/C
unit must use a Thermal Expansion Valve (TXV).
A Clutch Cycling Orifice Tube (CCOT) cannot be
used.
13. Compressor discharge gas temperature should
never exceed 130°C [266°F] under any driving or
idle conditions.
14. Do not alter or change the pulley size.
15. If designing an independent refrigerant loop (second
compressor, condenser, etc.) for an auxiliary A/C
system on a chassis cab vehicle, DO NOT order
either of the E-Series Auxiliary Heater/ A/C
Connector prep packages.
16. If adding auxiliary A/C to an F-Series Chassis Cab
system, no prep packages are available. Tap into
the system using custom lines that obtain the liquid
between the receiver drier and front TXV, and return
the suction line between the front TXV and the
compressor. The secondary evaporator must use a
TXV.
For additional information, refer to the SVE Bulletin
Q-195, “2011 F-Series Super Duty with Aftermarket
Auxiliary A/C System Control”, available online at
www.fleet.ford.com/truckbbas under the “Bulletins”
tab.
E-SERIES OPTIONAL A/C PREP PACKAGES
1. The A/C Prep Package (available on Stripped
Chassis only) consists of a compressor and
condenser only with computer logic inside the
Powertrain Control Module to interface with the
compressor. In addition, a dedicated pressure
transducer, included in dunnage, replaces the
traditional A/C high pressure switch; for additional
information, see SVE Bulletin Q-230, “2016 ESeries A/C Pressure Transducer Change”, available
online at www.fleet.ford.com/truckbbas under the
“Bulletins” tab.
2. The Auxiliary Heater/ A/C Connector Prep Package,
and Auxiliary Heater/ A/C Connector Prep Package
with Rear Controls (E-350/450 Cutaway only)
consists of an AUX blower control switch,
compressor, condenser, front CCOT HVAC
assembly, accumulator, and connection points for a
TXV controlled AUX A/C unit.
3. Information on determining air conditioning
refrigerant and lubricant quantities are outlined on
the Ford Truck Quality Program Guidelines web site
www.fleet.ford.com/truckbbas/topics/guidebook.html
2016
MODEL YEAR
Body Builders Layout Book
7
DESIGN
EXHAUST SYSTEM
WARNING:
VEHICLE OPERATING TEMPERATURES:
Some trucks manufactured by Ford Motor Company
may exhibit high engine compartment and exhaust
system temperatures in certain operating modes.
Components, including exhaust heat shielding
systems, have been installed as standard equipment
on some vehicles in an effort to provide thermal
protection against such temperatures. Aftermarket
equipment installers or intermediate and final stage
manufacturers are responsible for providing thermal
protection (e.g., underbody heat shields) for any
structure or equipment added to the vehicle and
should not remove any components or exhaust heat
shielding installed on the vehicle by Ford Motor
Company.
1. Do not substitute exhaust system components or
add to those furnished by Ford, except as noted in
this section. Such a substitution or addition may
adversely affect engine performance or emissions
system effectiveness.
2. Do not change the position or routing of the exhaust
system components. Such a change may affect the
amount of heat transferred to body, chassis, or
powertrain components, particularly fuel system
components. Specifically, do not add dual exhausts
or reroute exhaust components to the left side of the
vehicle.
3. Do not remove or modify existing heat shields. Ford
underbody heat shields are installed on vehicles to
provide heat protection for the vehicle floor and
body mounting system, and must remain in place on
the completed vehicle.
2016
DESIGN RECOMMENDATIONS
EXHAUST SYSTEM / FORD BODY COMPONENTS
4. Exhaust heat shields should be added by a body
builder and should extend far enough beyond the
exhaust system components to protect underbody
surfaces from heat radiated at any angle. Add
shields over the muffler and exhaust pipe kick-up
areas.
5. Do not remove Ford furnished exhaust clamps and
hangers.
6. An additional exhaust hanger should be installed, if
appropriate, to support extended tailpipe length
necessitated by body dimensions.
7. Do not make a rigid connection between the
exhaust system and the body.
8. Do not apply body undercoating on the fuel tank,
fuel fill hose, or fuel fill vent hoses. The extra
insulation on these components may cause
excessive heat build-up or possible material
incompatibility concerns (See Figure E).
9. Do not apply body undercoating within twelve
inches of the area directly above the exhaust, on
any components within twelve inches of the
exhaust, or to any part of any exhaust system.
Undercoating will smoke or burn if subjected to high
heat (See Figure E).
BOTTOM VIEW SHOWN
FIGURE E - DO NOT APPLY UNDERCOATING IN SHADED AREA
10. Extensions to the exhaust outlet pipe should direct
exhaust away from the body to minimize the
possibility of fumes entering the vehicle. Extensions
should also protrude beyond the vertical body
surface. Transit Chassis Cab and Cutaway vehicles
include an exhaust extension in dunnage; for further
information, reference the Transit Body Equipment
Mounting Manual (BEMM), available online at
www.fleet.ford.com/truckbbas
under
the
“Publications” tab.
11. Install all underbody plumbing for heaters, air
conditioners, and other accessories so that they are
not installed against sharp surfaces or jagged
edges. Protect from exhaust heat when routing.
12. Use only stainless steel for any exhaust system
modifications or additions.
13. Exhaust system revisions should consider thermal
expansion of materials and the effect on design
clearances.
FORD BODY COMPONENTS
1. Modifications to doors, roof, or body side panels
may have an effect on F/CMVSS 208, 210, 212,
214, 219, and 301 compliance. Refer to the
Statements of Conformity section in the Incomplete
Vehicle Manual for compliance representations.
2. Running boards or entry steps should use a
mounting system that will attach only to the body.
The Ford body to frame isolators allow body
movement which may loosen fasteners. A combined
frame and body mounting system may cause frame
induced noise, vibration, and harshness (NVH) to
transfer through such a mounting system into the
body.
3. Use a butyl type sealer on trimmed body sheet
metal panels to prevent corrosion.
4. Temporary mounting pads may eliminate chipping
and scratches when accessories are installed.
5. Select materials which will not have a corrosive
action with each other.
6. Additional fresh air vents should be located so that
engine exhaust cannot be drawn into the vehicle.
MODEL YEAR
7. When adding holes to the floor of the vehicle,
consideration must be given to all components
below the floor. The use of drill stops is
recommended.
8. Fasteners added to the floor should not point at the
fuel tank or the fasteners should have an
appropriate shield. Components with sharp edges
should have an appropriate shield to eliminate the
possibility of fuel tank penetration in crash
situations.
9. Components added to the E-Series engine cover
should allow for easy removal. Refer to the
Statements of Conformity in the Incomplete Vehicle
Manual or the Occupant Protection Zone
requirements for the engine cover and other
affected areas in the Safety / Emissions section.
10. The E-Series engine cover seal requires that
carpeting and insulation should be installed as
shown in Figure F.
11. Power operated windows, a partition, or roof panel
systems, when added to a vehicle with a GVWR of
4536 kg [10,000 lb] or less, must comply with the
requirements of F/CMVSS 118; refer to the
Statements of Conformity in the Incomplete Vehicle
Manual.
12. When a Second Unit Body (SUB) or rear closure
panel is attached directly to the Cutaway body,
difficulty may be experienced when closing doors
due to air pressure build up. It is recommended that
vent(s) be installed to allow “ONE WAY” pressure
release from the inside of the cab to the outside.
The recommended minimum size of the venting is
36 square inches.
ENGINE
COVER
SEAL
(RUBBER)
ENGINE COVER
INSULATION
FLOOR PAN
CARPET
TYPICAL SECTION
CARPETING INSTALLATION
AT ENGINE COVER
INSULATION
FIGURE F - E-SERIES ENGINE COVER SEAL
www.fleet.ford.com/truckbbas
Body Builders Layout Book
8
DESIGN RECOMMENDATIONS
WHEELS & TIRES / TPMS
DESIGN
WHEELS AND TIRES
WARNING:
Some aftermarket wheel assemblies may not be
compatible with some vehicles and should not be
used. Use of incompatible wheel assemblies may
result in wheel fractures, separation, with the potential
for an accident, and injury to occupants. Ford
recommends that only wheel assemblies approved
and released by Ford Motor Company for the vehicle
model should be used.
WARNING:
Re-torque all lug nuts to specification. It is imperative
that the dealer re-torque all wheel lug nuts on all
vehicles prior to delivery to the final vehicle
purchaser. Dual rear wheel vehicles may be shipped
with the outer rear wheels removed and, therefore,
the dealer must ensure that the lug nuts are retorqued to the proper specification before the vehicle
is delivered to the final vehicle purchaser. Improperly
tightened lug nuts could loosen and allow the wheel
to come off while the vehicle is in motion, causing
loss of control.
1. Use only wheels with the same load capacity, rim
width, rim offset, and mounting configuration as
those originally installed on the vehicle. Consult an
authorized Ford dealer for correct wheel load
capacity, size, and usage. Wheels used must
conform to the F/CMVSS 120. The use of any wheel
or tire, other than those originally installed on the
vehicle as manufactured by Ford, may adversely
affect load carrying capacity, handling, bearing life,
ride, braking performance, speedometer/odometer
accuracy, automatic transmission shift timing, Tire
Pressure Monitoring System (TPMS) operation and
tire/wheel clearance of the body and chassis.
2. Use only replacement tires that are the same size,
load index, speed rating and type (such as P-metric
versus LT-metric or all season versus all-terrain) as
those
originally
provided
by
Ford.
The
recommended tire and wheel size may be found on
either the Safety Compliance Certification Label or
the Tire Label which is located on the B-pillar or
edge of the driver’s door. If this information is not
found on these labels, consult a Ford dealer. Use of
any tire or wheel not recommended by Ford can
affect the safety and performance of the vehicle,
which could result in an increased risk of loss of
vehicle control, vehicle rollover, personal injury and
death. Additionally, the use of non-recommended
tires and wheels could cause steering, suspension,
axle or transfer case/power transfer unit failure. If
you have questions regarding tire replacement,
contact an authorized Ford dealer. Tires used must
conform to FMVSS 119 (New Pneumatic Tires for
Motor Vehicles) and FMVSS 139 (New Pneumatic
Radial Tires for Light Vehicles) in the United States,
or to the Motor Vehicle Tire Safety Regulations in
Canada.
3. SRW vehicles with a GVWR of 4536 kg [10,000 lb]
or less must comply with FMVSS 138 (Tire Pressure
Monitoring Systems). Reference the Tire Pressure
Monitoring System (TPMS) section in Owner Guide,
Ford Shop Manual & FMVSS 139 (New Pneumatic
Tires for Light Vehicles).
4. If you loosen or remove wheel lug nuts for any
reason, or have in your possession a vehicle at any
of the mileage intervals listed in the Wheel Lug Nut
Table below, check the lug nut torque and re-torque
to the specifications as listed in the table. Follow the
recommended Maintenance Procedure.
WHEEL LUG NUT TORQUE SPECIFICATIONS
WHEEL LUG
RE-TORQUE
NUT TORQUE
MILEAGE
VEHICLE TYPE
Km
Miles
Nm
Ft Lb
E-Series
E-350 SRW
E-350/450 DRW
F-Series
Super Duty
F-250/350 SRW
Super Duty
F-350/450/550 DRW
Transit
Transit-150/250/350
SRW
Transit-350 HD
DRW
www.fleet.ford.com/truckbbas
160
160
800
100
100
500
203
150
190
140
160
100
224
165
160
800
100
500
224
165
160
100
200
148
160
800
100
500
200
148
BRAKE COMPONENTS:
WARNING: Brake line damage or corrosion
Do not wrap brake lines with any material that could
cause water, dirt, sand or other foreign material to
accumulate around the lines, which could potentially
result in brake line damage or corrosion.
2016
MODEL YEAR
TIRE PRESSURE MONITORING SYSTEM (TPMS)
Single Rear Wheel (SRW) vehicles with a GVWR of
10,000 lbs (4356 kg) or less, as manufactured by Ford
Motor Company, comply with FMVSS 138 Tire Pressure
Monitoring System. Operational and wheel replacement
information is provided in the vehicle’s Owner Guide
and Ford Shop Manual.
NOTE: The Tire Pressure Monitoring System is subject
to interference from the addition of metallic structures
between the wheel-mounted sensor transmitters and
the on-board receiver. Additionally, TPMS is subject to
interference from any added equipment or device that
emits radio frequency (RF) energy.
The vehicle, when completed, will conform to Standard
138, Tire Pressure Monitoring Systems, if:
● No alterations are made to the tire pressure sensors
(valve stems), wheels, tires, recommended tire
pressures, electrical Smart Power Distribution
Junction Box, instrument cluster, instrument panel
wiring, or software calibrations
● Wheel bases are not lengthened beyond 176 inches
● After vehicle upfit, function of the Tire Pressure
Monitoring System is verified in accordance with
FMVSS 138
Body Builders Layout Book
9
DESIGN
SUSPENSION AND STEERING SYSTEM – VEHICLE
HANDLING INFORMATION
The weight of the body structure and its center of
gravity location (both longitudinally and vertically), as
well as the weight and positioning of the cargo load, are
important to the handling of the completed vehicle.
Subsequent stage manufacturers should note that
matching a body to a chassis in a manner appropriate
for the intended use of the vehicle is the responsibility
of the final stage manufacturer. Following the
representations in this book or the Incomplete Vehicle
Manual, with respect to center of gravity locations and
body weights for compliance with Federal or Canadian
Motor Vehicle Safety Standards, is only part of the task
of producing a completed vehicle that handles
appropriately in service.
1. Front end alignment warranty policy for incomplete
vehicles is based upon the completed vehicle
remaining within OEM weight ratings, vehicle
attitude, suspension and wheel/tire guidelines, and
other characteristics affecting wheel alignment.
Exceeding or modifying these restrictions may
jeopardize related warranty.
IMPORTANT: The final-stage manufacturer is
responsible for verifying that the front wheel toe is
within Ford specifications on completed vehicles. The
steering wheel clear vision (horizontal or level
orientation of the steering wheel) should also be
maintained when resetting wheel toe. These
specifications are found in the General Suspension
section of the Ford Shop Manual.
2. Modifications
made
by
subsequent
stage
manufacturers, particularly those that significantly
affect vehicle ride heights, may cause vehicle
control problems during excessively sharp turns or
other abrupt steering maneuvers, possibly leading
to rollover or other accidents that could result in
death or serious injury.
IMPORTANT:
The steering gear, intermediate shaft, coupling shaft,
linkage, column, and steering wheel should not be
altered nor relocated. Steering linkage travel should
not be restricted.
www.fleet.ford.com/truckbbas
DESIGN RECOMMENDATIONS
SUSPENSION & STEERING / ENGINE
3. Ford Motor Company front and rear GAWRs and
GVWR must not be exceeded.
4. Front or rear suspension components should not be
drilled, cut, welded, or relocated for any reason.
5. Welding to the frame in the steering gear area is not
recommended.
6. If rear suspension spacers are used between the
spring and axle seats to accommodate side-to-side
variations, they should not exceed 3/8 inch. The
spacers should not exceed the profile of the axle
spring seat. Additional spacing may adversely affect
driveline angles and axle system package
clearance. Also affected are spring stress limits from
excessive jounce travel.
7. Do not use any suspension component as a welding
ground.
8. When welding or cutting near suspension
components, shield and protect all springs and
rubber components from heat penetration and
welding splatter.
9. Any add-on device mounted on the steering column,
shroud, multifunction switch, or gear selector lever,
must not affect steering column angles, tilt
mechanism (if so equipped), range of operation, or
steering column mounting hardware. Any such
device must not interfere with steering column
collapse stroke travel during crash situations or air
bag deployment.
10. Vehicles equipped with an air suspension system
must verify that the settings are correct once the
vehicle is completed by the final stage
manufacturer. Refer to the applicable Ford truck
workshop service manual for the complete
procedure.
NOTE:
Ford Motor Company provides Type I and Type II
FMVSS/CMVSS 105 compliance statements for
vehicles built to factory standard or optional
specifications. Suspenion ride height and/or spring
rate modifications are factors that may affect
compliance to this Standard. If an alterer or final stage
manufacturer modifies the suspension ride height or
spring rate of the factory-equipped vehicle, then they
are responsible for engineering analysis or physical
testing to ensure compliance and sign-off to Standard
105.
ENGINE
1. Refer to Emission Control Modifications in the
Safety/Emission section of this book prior to making
modifications to any engine component that could
affect the emission certification.
2. The engine should not be operated with the hood up
or removed. This may allow excessive unforced air
to circulate, potentially having an adverse effect on
the cooling system.
3. Do not use manual throttle kickers.
4. When using electric throttle kickers on gasoline
engines, set the high idle RPM at as low as possible
to obtain the required performance. The idle speed
must be set when the engine is at normal operating
temperature and under normal load. This RPM
setting should be affixed to the vehicle and should
be checked after the 2,000 mile brake-in engine
tune up. This information should be provided to the
purchasers. The addition of throttle kickers may
affect electronic transmission operation.
5. An auxiliary crankshaft bearing support is required
on all modular gas engines before a FEAD-mounted
PTO can be installed. Refer to the Power Take-Off
section of this book.
6. Do not tap into the electrical circuits attached to the
Accelerator Pedal Position Sensor (APP) on the
accelerator control. Do not bypass the electrical
circuits attached to the APP. See figure below for a
typical accelerator control.
2016
MODEL YEAR
7. Installation of a gasoline engine speed governor is
permissible, provided the governor design is
compatible with each respective throttle body for the
individual engine application and it does not exceed
the specified engine maximum RPM. It must also
meet all noise and engine emission requirements.
Governor installations may affect electronically
controlled transmissions. Contact the Ford Truck
Body Builders Advisory Service before installing.
Body Builders Layout Book
10
DESIGN
DRIVELINE
1. Bulletin Q-14, “Guidelines for Modifying Truck
Drivelines,”
is
available
at
www.fleet.ford.com/truckbbas/ from the list under
the “Bulletins” tab. Any deviation from Ford Motor
Company specifications may adversely affect
powertrain system operation including engine and
transmission, or component reliability. Subsequent
stage manufacturers or installers are responsible to
maintain Ford specifications in the completion of
such modifications.
2. Rear axle vent and hose, if installed, must not be
bent, pinched, or obstructed so that normal
“breathing” of the rear axle is provided.
3. On all rear axle assemblies, additional bracket bars
or supports must not be welded to the axle
assembly. Attachment of any equalizing-type trailer
hitch or auxiliary suspension systems (springs) must
not be attached to the rear axle assembly.
TRANSMISSION
1. The transmission oil filler tube and dipstick must not
be altered by bending, lengthening, or shortening,
and must be readily accessible in the engine
compartment for checking lubricant level. NEVER
ATTACH
ANY
COMPONENT
TO
THE
TRANSMISSION FILLER AND DIPSTICK TUBE.
2. The installed engine angle must not be altered. The
relative position of engine and transmission to shift
linkage must not be altered.
3. Transmission vent must not be altered, pinched, or
collapsed, and the vent opening must not be
restricted or relocated.
4. Adequate tool clearance and suitable access
openings for transmission adjustments must be
provided. Transmission removal provisions must
also be considered.
5. Transmission oil cooler lines should not be kinked,
bent, or restricted. All oil cooler lines must be
properly retained with adequate clips. The trucktype external oil cooler must not be “boxed in”,
which would restrict adequate air circulation. Use
only Ford factory coolers. Some automatic
transmissions are equipped with “Stand Alone”
transmissions fluid coolers. Vehicles equipped with
this new oil-to-air cooler (OTA) may not have a
transmission fluid cooler in the radiator. The OTA is
located in front of the radiator and will require
replacement every time the transmission is
reworked or replaced. The cooler lines and Cooler
Bypass Valve (CBV) must also be cleaned and
backflushed.
www.fleet.ford.com/truckbbas
DESIGN RECOMMENDATIONS
DRIVELINE / TRANSMISSION / FRAME / JACK
CAUTION:
Failure to replace the OTA, backflush the cooler lines
and cooler bypass valve (CBV) may result in
transmission assembly internal damage.
6. Transmission shift cable, transmission outer shift
lever, and shift cable bracket must not be altered
and must have provisions for adjusting tool
clearance. A severe duty shift cable (booted) is
available as a service part, from a Ford Dealer, for
Super Duty F-Series vehicles which experience
extensive off-road use.
7. Some automatic transmissions may be equipped
with a transmission cooler bypass system. The
purpose of the cooler bypass valve is to allow some
transmission fluid to bypass the transmission fluid
coolers and return to the transmission sump during
cold weather operation. This provides a faster
transmission fluid warm up and increased lube flow
during cold weather operation. Do not remove nor
modify this system or transmission damage may
occur. Do not use the cooler bypass line as a fitting
point. Vehicles equipped with transmission cooler
bypass will NOT have a hot water feed circuit from
the water pump to the radiator tank containing the
transmission cooler.
FRAME
WARNING:
Failure to follow the recommendations below may
weaken the vehicle frame, which could result in death
or serious injury.
1. Holes that would weaken the frame sidemember
should not be drilled in the frame. Holes are not to
be drilled in the sidemember’s top or bottom flange.
2. Holes to mount brackets, out-riggers, and supports,
may be drilled in the vertical frame side rail web with
the following restrictions:
● Material between edge of hole and inside of upper
or lower flange must not be less than 1.50 inch for
low carbon steel (36,000 PSI yield).
● The minimum edge distance between any two
holes up to 0.625 inch diameter must be 1.00 inch.
For larger than 0.625 inch diameter holes, the
minimum edge distance must be 1.5 times the
diameter of the largest hole.
● 0.75 inch is maximum hole diameter.
● Avoid close vertical succession of fasteners.
● All
attaching fasteners, including flat washers,
must be of high strength steel (Grade 8).
CAUTION:
Do not use the cooler bypass valve (CBV) as a handle
– damage to the CBV and transmission may result. This
also causes leaks.
WARNING:
When welding is performed anywhere on the vehicle,
precautionary measures should be taken to prevent
damage to electrical system wiring or components.
8. Transmission service identification tags must not be
removed nor destroyed. If the transmission is
reworked or replaced, the tag should be attached to
new transmission.
9. Electronically controlled automatic transmission wire
harness routing location, wire harness locating clips,
all heat shielding, and clearance to the exhaust
must be maintained as installed from the assembly
plant.
10. Body structures should not be less than 1.00 inch
from the rectangular vent holes on the top surface
of the manual transmission housing.
11. SVE Bulletins Q-14 (Drivelines) and Q-18
(Wheelbases)
contain
additional
detailed
information on modifications which may affect
transmissions. To obtain a copy, go to
www.fleet.ford.com/truckbbas/ and select from the
list under the “Bulletins” tab.
3. Prior to welding, any parts which could be damaged
by excessive temperatures should be removed or
adequately shielded. Also, prior to welding,
disconnect both batteries, and the PCM. The
welding ground clamp should be positioned as close
to the affected welding area as possible. Computer
processors should be removed if welding is to be
done within their close proximity. Welding cables
should never be allowed to lay on, near, or across
any electrical wiring or electronic component during
welding. After welding, when parts are cool,
carefully inspect wiring and electrical components
for shorts or other damage which could draw
excessive currents and possibly cause an electrical
system short when the battery is reconnected.
4. Do not weld on frame flanges, including the bend
radii.
5. When welding low carbon steel side rails (36,000
PSI yield strength), emphasis should be placed
upon weld application techniques to avoid stress
risers that may adversely affect frame operating
stresses. When welding within 4 inches of any
crossmember or suspension rivets, remove the
rivets and replace with Grade 8 bolts and nuts.
2016
MODEL YEAR
6. Do not modify or alter the convoluted frame sections
in the area behind the front bumper. Modifications or
alterations could have an adverse effect on vehicle
performance in a crash situation.
7. Wheelbase alteration and frame extension
guidelines for E-Series Super Duty Cutaway are
available in Bulletin Q-18 and for F-650/750 in
Bulletin Q-140. Go to www.fleet.ford.com/truckbbas/
and select from the list under the “Bulletins” tab.
Transit frame extension guidance is referenced in
Bulletin Q-225 with a link to the Transit Body
Equipment Mounting Manual (BEMM). Any deviation
from the original vehicle specification will become
the responsibility of the subsequent stage
manufacturer or installer. This may affect
transmission operation and durability.
8. Recommend the use of OEM front tow hooks only.
See the Owner's Manual for towing instructions.
9. To prevent collapse of the frame side rail flanges,
when U-bolts are used for the attachment of bodies
to the truck chassis, vertical spacer bars must be
used between the upper and lower flanges at each
U-bolt.
10. All E-Series Super Duty Cutaways or Stripped
Chassis with a 176 inch wheelbase and equipped
with a 55 gallon fuel tank will require an 18 inch
minimum frame extension to provide for an
adequate departure angle fuel tank clearance.
11. School bus rear bumpers should meet the following
recommended minimum specifications: height 203.2
mm [8.00 in] at 10,050 lbs, and 241.3 mm [9.50 in]
over 10,050 lbs; 50.8 mm [2.00 in] upper and lower
flange; 304.8 mm [12.00 in] wrap-around; 4.7 mm
[0.187 in] thick. See the Incomplete Vehicle Manual
for additional information.
JACK
If a jack is provided, it must be stowed in a location
accessible to the operator.
Body Builders Layout Book
11
DESIGN RECOMMENDATIONS
AMBULANCE BUILDER GUIDELINES
DESIGN
NOTE:
A Ford vehicle is suitable for final stage manufacture
into an ambulance only if equipped with a Ford
Ambulance Preparation Package. Ford urges
ambulance
manufacturers
to
follow
the
recommendations furnished in the Incomplete Vehicle
Manual, (and any pertinent supplements), and the
Qualified Vehicle Modifier (QVM) guidelines. Using a
Ford vehicle without the Ford Ambulance Preparation
Package to produce an ambulance voids the Ford
warranty and could result in elevated underbody
temperatures, fuel over-pressurization and the risk of
fuel expulsion and fires. Vehicles equipped with Ford
Ambulance Preparation Packages have labels located
on (the inside) driver door lock pillar that state that the
vehicle is so equipped.
INFORMATION
Ford
urges
careful
consideration
of
the
recommendations that follow. They are based on
analyses of component and vehicle tests, actual service
situations, and engineering judgments. Disregard of
these recommendations may affect the durability,
reliability, handling and performance characteristics of a
completed vehicle and may elevate underbody
temperatures and increase the potential for fire, or may
affect the safety of the occupants in the event of an
accident.
These recommendations are supplemental to U.S. And
Canadian
Motor
Vehicle
Safety
compliance
representations provided in the Incomplete Vehicle
Manual. Additional information is also provided in this
book and the Ford Truck Shop Manual which may be
helpful
to
subsequent
stage
manufacturers.
Subsequent stage manufacturers are encouraged to
contact the Ford Truck Body Builder Advisory Service if
they have
any questions
concerning
these
recommendations.
ACCESSORIES SHOULD
NOT BLOCK AIRFLOW
IN SHADED AREAS
KEEP THIS
AREA CLEAR
ENGINE COOLING RADIATOR
AIR CONDITIONER CONDENSER
E-SERIES
SUPER DUTY
www.fleet.ford.com/truckbbas
F-SERIES
SUPER DUTY
GUIDELINES
1. All Exhaust System and Underbody Heat
Management statements in the SECOND UNIT
BODY
MOUNTING
and
DESIGN
RECOMMENDATIONS sections of this book apply
to completed ambulance type vehicles
2. Data concerning the effect of hood louvers is
inconclusive. If a body builder chooses to add them,
the opening should be directed rearward to avoid
recirculating discharged hot air through the radiator.
NOTE:
The vehicle interior vent air enters the passenger
compartment at the base of the windshield. Louvers
may direct heated air or fumes toward this opening.
Removal of the underhood insulation may affect
Exterior Noise compliance. See the Exterior Noise
information in the Safety / Emissions section of this
book.
3. To deal with higher electrical loads, Ford vehicles
with the Ambulance Preparation Package may be
equipped with dual alternators, dual batteries and
heavy duty wiring to handle higher electrical loads.
Added wiring should be of sufficient capacity to
handle the higher current. The alternator should not
be modified, altered nor replaced.
2016
MODEL YEAR
4. Added Second Unit Body (SUB) vents, especially
powered vents, should be located away from the
fuel filler, fuel venting areas and exhaust to avoid
fuel fumes and vapors entering the interior of the
vehicle.
5. Equipment such as flashing lights and sirens, spare
tire, or any other accessories should not be installed
in the grille area forward of the radiator or air
cleaner air inlet. Doing so restricts proper airflow
through the radiator and engine compartment.
Lights, speakers, or sirens should not be mounted
in the center area of the grille. Equipment should be
mounted as far outboard as possible, not to exceed
90 square inches each or 180 square inches
combined in area.
6. An ambulance is not to be used as a tow vehicle.
Body Builders Layout Book
12
DESIGN
GENERAL
●
Store vehicles in a dry ventilated place; protect from
sunlight if possible.
●
If vehicles are stored outside, provide regular
maintenance against rust and damage.
●
Ensure chassis interior and dunnage box is not
exposed to the weather and the potential damage
that can occur.
●
On cutaways and right-door delete models, ensure
back panel plastic sheet is intact and temporary door
(right-hand delete option) is in place when vehicles
are stored outside or moved.
●
Any chassis with an incomplete roof modification
should not be stored outside unless appropriately
protected.
BODY
●
Wash vehicle thoroughly to remove dirt, grease, oil,
tar, or mud from exterior surfaces, rear wheel
housing, and underside of front fender.
●
Periodically wash vehicles stored in exposed
locations.
●
Touch up exposed raw or primed metal to provide
rust protection.
●
Cover chrome and stainless steel parts with a thick
coat of auto wax to prevent discoloration. Rewax as
necessary when the vehicle is washed.
●
Lubricate all hoods, door hinges and latches with a
light grade oil.
CAUTION: Keep all rubber parts free from oil and
solvents.
●
Cover the interior soft trim to prevent fading, if stored
in exposed location.
●
Body Builders should review their vehicle receiving,
storage and production handling procedures to
assure the chassis interior and dunnage box are not
exposed to the weather and the potential damage
that can occur. On cutaway chassis, builders should
verify that the back panel plastic sheet is intact and
the temporary door (right-hand door delete option)
are in place when vehicles are stored outside or
moved. Any chassis with an incomplete roof
modification should not be stored outside unless
appropriately protected.
www.fleet.ford.com/truckbbas
DESIGN RECOMMENDATIONS
NEW VEHICLE STORAGE GUIDELINES
ENGINE
●
Start the engine every 15 days and move the vehicle
at least 25 feet. Run it at fast idle until it reaches
normal operating temperature.
●
Shift the transmission into all gears while engine is
running at idle speed.
FUEL SYSTEM
●
Regularly move vehicles short distances to mix fuel
anti-oxidation agents.
NOTE: During extended periods, if vehicle is stored
for 60 days or more, gasoline may deteriorate due to
oxidation. This can damage rubbers and other
polymers in the fuel systems such as fuel pressure
regulator diaphragms and fuel line connector seals.
It may also clog small orifices. Diesel fuel
deterioration in the form of fuel separation, sludge
formation, and bacterial growth can cause
restrictions in fuel supply lines, filters and sticking of
fuel-injection system components.
A commercially available gasoline fuel stabilizer
(“Sta-Bil” or equivalent) should be added to gasolinepowered vehicles or a diesel fuel stabilizer (“Fire
Prep 100” or equivalent) to diesel-powered vehicles
whenever actual or expected storage periods exceed
60 days. The manufacturer’s instructions packaged
with product should be followed. The vehicles should
then be operated at an idle speed to circulate the
additive throughout the fuel system.
A volatile, corrosion inhibitor (NOx Rust VCI 105" or
equivalent) added to the fuel will protect the fuel tank
inner surface from corrosion. Follow instructions
packaged with product.
COOLING SYSTEM
●
Maintain appropriate antifreeze protection against
freezing temperatures.
●
Only use coolant as recommended in your vehicle
owner's manual.
BATTERY
●
Check and recharge as necessary.
●
Keep connections clean and covered with a light
coat of grease.
2016
MODEL YEAR
BRAKES
●
Make sure brakes and the parking brake are fully
released.
TIRES
●
Maintain recommended air pressures.
MISCELLANEOUS
●
Verify that all linkages, cables, clevis pins, and
levers under the vehicle are covered with grease to
prevent rust.
●
Move trucks at least 25 feet every 15 days to
lubricate working parts and prevent corrosion.
TRANSMISSION
●
Run engine to normal operating temperature.
●
Shift the transmission into all gears with engine
running at idle speed.
●
Check fluid level and condition (no water
contamination, etc.).
●
Stripped Chassis vehicles – cover transmission to
prevent water from entering through the vent.
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